Electrical box contact with stress limitation

Abstract

A box receptacle contact or terminal 10 is used in an electrical connector 2 , typically of type employing multiple terminals 10 . The box receptacle contact 10 has a cantilever spring contact beam 12 extending from a receptacle base 14 . The spring contract arm 12 is reversely bent intermediate the ends of the spring contact beam to form a reversely bent section 20 at a forward portion of the spring contact arm 12 . The spring contact beam is outwardly deflectable relative to the receptacle base 14 when mated with a mating contact 80 , such as a blade or pin terminal. Two receptacle sidewalls 42, 44 are formed upwardly from the receptacle base 14 on opposite sides of the spring contact beam 12 . Lateral projections 38, 40 extend from edges of the spring contact beam 12 between the cantilever spring base 16 and the reversely bent section 20 . The lateral projections 38, 40 extend beneath the sidewalls 42, 44 to limit inward deflection of the spring contact beam 12 relative to the receptacle base 14 . In this manner the cantilever contact beam. 12 is not be damaged or overstressed when the terminal 10 is inserted into a connector housing cavity 6.

I claim:  
     
       1. A box receptacle contact for use in an electrical connector comprising: 
       a spring contact beam extending from a receptacle base, the spring contact beam being reversely bent between ends of the spring contact beam to form a reversely bent section at a forward portion of the spring contact beam, the spring contact beam being outwardly deflectable relative to the receptacle base when mated with a mating contact;  
       first and second receptacle sidewalls formed upwardly from the receptacle base on opposite sides of the spring contact beam; and  
       at least one lateral projection extending from an edge of the spring contact beam between the base and the reversely bent section, the lateral projection extending beneath one of the sidewalls to limit inward deflection of the spring contact beam relative to the receptacle base.  
     
     
       2. The box receptacle contact of claim  1  wherein projections extend laterally from opposite edges of the spring contact beam and extend beneath the first and second receptacle sidewalls. 
     
     
       3. The box receptacle contact of claim  2  wherein the spring contact beam is inwardly tapered from the lateral projections so the spring contact beam is narrower at a juncture of the spring contact beam and the base than adjacent the lateral projections. 
     
     
       4. The box receptacle contact of claim  2  wherein a notch section is formed in each receptacle sidewall, the notch sections having a lower edge recessed relative to adjacent sections of the sidewalls, and wherein the lateral projections extend beneath the notched sections. 
     
     
       5. The box receptacle contact of claim  4  wherein the notch sections are recessed above the receptacle base. 
     
     
       6. The box receptacle contact of claim  2  wherein the spring contact beam extends from the reversely bent section adjacent the forward portion, upwardly and rearwardly to a contact surface adjacent a free end of the spring contact beam, the contact surface and the juncture of the spring contact beam and the base both being positioned rearwardly relative to the lateral projections. 
     
     
       7. The box receptacle contact of claim  6  wherein the spring contact beam includes an aperture between the reversely bent section at the forward portion and the free end to form a contact surface with four points of contact with a mating terminal. 
     
     
       8. The box receptacle contact of claim  2  wherein a opening in the receptacle base is located behind the spring contact beam. 
     
     
       9. The box receptacle contact of claim  8  wherein stress in the receptacle base due to deflection of the spring beam contact are confined to the area between the first and second sidewalls and the opening. 
     
     
       10. The box receptacle contact of claim  2  wherein the overlapping top walls, extending from top edges of the first and second sidewalls form a top enclosure of the box receptacle. 
     
     
       11. An electrical connector comprising a molded housing and contact terminals positioned in housing cavities, the housing including latches extending into the cavities to retain the contact terminals in the housing, wherein the contact terminals include a cantilever spring beam deflectable in a first direction when mated to mating terminals to generate a mating force, the cantilever spring beam including projections extending from opposite edges and abutting opposed surfaces overlapping the projections when deflected in a second direction to limit deflection in the second direction, the contact terminals being insertable into the housing cavities with the latches on the housing engaging the cantilever spring beam and deflecting the cantilever spring beam in the second direction during insertion of the contact terminals into the housing cavities. 
     
     
       12. The electrical connector of claim  11  wherein the opposing surfaces are located on the contact terminals. 
     
     
       13. The electrical connector of claim  11  wherein the contact terminals comprise receptacle terminals. 
     
     
       14. The electrical connector of claim  13  wherein the receptacle terminals comprise box receptacles having sidewalls extending adjacent to the cantilever spring beam, which extends from a receptacle base. 
     
     
       15. The electrical connector of claim  14  wherein the opposing surfaces are located on edges of the sidewalls adjacent to the receptacle base. 
     
     
       16. The electrical connector of claim  11  wherein the contact terminals include openings into which the housing latches extend to engage the contact terminals for retention in the housing cavities, the openings being located adjacent to a base of the cantilever spring beams. 
     
     
       17. The electrical connector of claim  11  wherein each cantilever spring beam extends from a cantilever base to a reversely bent forward section, the cantilever spring beam extending rearwardly from the forward section to a free end of the cantilever spring beam, the projections being located between the cantilever base and the reversely bent forward section. 
     
     
       18. The electrical connector of claim  17  wherein the reversely bent forward sections comprise leading ends of the contact terminals as the contact terminals are inserted into the housing cavities. 
     
     
       19. The electrical connector of claim  11  further comprising a terminal position assurance member engagable with the housing latches to prevent deflection of the housing latches. 
     
     
       20. A female electrical terminal suitable for use in establishing electrical connection with mating terminal blades of different lengths, the electrical receptacle terminal comprising: 
       a cantilever spring contact beam having a first section extending from a cantilever base to a reversely bent section located between the first section and a second section, which extends between the reversely bent section and a distal end with a blade contact surface being located adjacent the distal end, the first section being more compliant than the second section, which extends at an acute angle relative to the first section; and  
       means on the first section for limiting deflection of the cantilever spring contact beam due to forces applied to the first section and directed toward the second section.